Motorola Dp3400 3401 3600 3601 Mototrbo Basic 6866574d29 E Manual

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-19
5.8.3 Specialized Test Equipment
This section summarizes the specialized test equipment necessary for testing the integrity of the  
series radios.
To ensure that the radio is truly a watertight unit , special testing, test procedures, and specialized 
test equipment are required. The special testing involves a vacuum check of the radio and pressure 
testing (troubleshooting) for water leaks if the vacuum  check fails. The specialized test equipment/
instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum 
check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table 
must not be used to perform these test.
5.8.4 Vacuum Pump Kit NLN9839
The vacuum pump kit includes a vacuum pump with  gauge, and a vacuum hose. A connector fitting 
(part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must 
be ordered separately, connects the vacuum hose to the radio’s chassis.
Figure 5-20.  Connector Fitting - Fitting Seal Pump Connector
5.8.5 Pressure Pump Kit NTN4265
The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the 
vacuum pump kit above, the connec tor fitting - fitting seal pair connects the pressure hose to the 
radio’s chassis.
5.8.6 Miscellaneous Hardware
Other items needed for testing the immersibility radio include:
• Large water container
• Deionized (DI) water
• A supply of replacement parts: Main seal O-ri ng, Battery Contact Seal, Breathing Vent Label 
and Breathing Vent Membrane. (Refer to Section 5.9.1 Display Model Exploded View and 
Parts List  on page 5-27 or Section 5.9.2 Non-Display Model Exploded View and Parts List  
on page 5-30.)
5.8.7 Vacuum Test
The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the 
radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly 
sealed, watertight unit. Before starting the vacuum test:
• Remove the battery.
Fitting Seal 
(part number 
3271133M01)
Connector Fitting  (part number 
5871134M01) 
						

							5-20Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
• Remove the universal connector dustcover  to expose the universal connector.
• Remove the breathing vent label and breathing vent membrane.
To conduct the vacuum test: 1. Attach antenna firmly to the radio.
2. Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by block-
ing off the open end of the hose and operating th e pump a few times. The actual reading of 
the gauge at this point is not important; it is  important that the gauge pointer remained steady, 
indicating no vacuum leaks in the pump.
3. Ensure that the fitting seal is attached to  the hose-to-chassis pump connector. Screw the 
pump connector into the tapped hole in the chassis.
4. Attach the open end of the hose to t he pointed end of the pump connector.
5. Place the radio on a flat surface  with the chassis facing upward.
6. Operate the pump until the gauge indicates 6 in . Hg of vacuum on the radio.Observe the 
gauge for approximately 1 minute.
• If the needle falls 0.5 in. Hg or less (one scale  interval, for example, from 6 in. Hg to 5.5 in. 
Hg), then the radio has passed the vacuum  test and is approved for immersibility. No 
additional testing will be required.
• If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 6 in. Hg to less  than 5.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if 
immersed. Additional troubleshooting of the radio will be required; comple te this procedure, 
then go to Section 5.8.8 Pressure Test.
7. Remove the vacuum hose and pump connector from the radio.
5.8.8 Pressure Test
Pressure testing the radio is necessary only if th e radio has failed the vacuum test. Do not perform 
the pressure test until th e vacuum test has been completed. Pressure testing involves creating a 
positive pressure condition inside the radio, imme rsing the radio in water, and observing the radio 
for a stream of bubbles (leak). Since all areas of th e radio are being checked, observe the entire unit 
carefully for the possibility of multiple leaks before completing this test.
To conduct the pressure test:
1. Screw the pump connector (with fitting seal) into the tapped hole in the chassis.
2. Attach one end of the pressure hose to the pump connector and the other end to the pressure 
pump.
3. Attach antenna firmly to the radio.
4. Operate the pump until the gauge reads approximately 1 psig.
5. Maintain the pressure at 1  psig and immerse the radio in to a water-filled container. 
6. Watch for any continuous series of bubbles. A  stream of bubbles indicates a sign of leakage.
CAUTION: Pressure any greater than 1 psig might push air around the main seal.
NOTE
Some air entrapment may cause the accumulati on of bubbles, especially in the grille area,
but the bubbles should not be continuous. 
						

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-21
7.Note all of the seal areas that show signs of  leakage. Pinpoint the problem(s) to one (or more) 
of the following areas:
• Front Housing
• Chassis (Main Seal O-ring)
• Battery Contact Seal
8. Remove the radio from the water container, and dry the radio thoroughly. Be especially care-
ful to dry the area around the main seal to prevent contamination of the internal electronics 
while the unit is open.
9. Remove the pump connector from the chassis.
10. Radio after performing Pressure Test must undergo baking process in a temperature chamber 
for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped 
inside the radio and prevent c ontamination of the internal electronics after reassembling the 
radio.
5.8.9 Troubleshooting Leak Areas
Before repairing any leak, first read all of the step s within the applicable section. This will help to 
eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot 
only the faulty seal areas listed in Section 5.8. 8 Pressure Test  on page 5-20, and when multiple 
leaks exist, in the order listed.
5.8.9.1  Front Housing
Do one or both of the following:
1. If a leak occurs at the Lens (Display Model s only), Universal Connector, chassis/Housing 
interface, PTT button area of the housing, repl ace the housing. Refer to Section 5.6 Radio 
Disassembly – Detailed  on page 5-5.
a. Remove the housing assembly from the radio.
b. Discard the housing assembly and main seal O-ring.
c. Install a new main seal O-ring around the chassis assembly according to Section 5.7.2  Chassis Reassembly  on page 5-14.
d. Install a new housing assembly to the radio.
e. Inspect the main seal for proper seating.
f. Observe carefully to ensure that the main  seal O-ring is not pinched between the 
housing and the chassis interface.
2. If the leak occurs at the control top area, remove the knobs in order to determine the leak 
location:
a. Conduct the Pressure Test.
b. Identify the leak location.
CAUTION: Keep the area around the chassis’s vacuum  port dry by ensuring that there is no water 
around it.
NOTE
Before reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal
in the defective area. 
						

							5-22Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
5.8.9.2  Chassis (Main Seal O-ring)
To replace the main seal O-ring:
1. Refer to Section 5.6.1 Front Cover from Chassis Disassembly  on page 5-5, remove the 
chassis assembly from the radio.
2. Refer to Section 5.6.2 Chassis Disassembly  on page 5-8, remove the Main Board from 
chassis.
3. Remove the main seal O-ring.
4. Inspect the seal area around the chassis for fore ign material that might prevent the main seal 
O-ring from sealing properly. 
5. Assemble a new O-ring; discard the old O-ring. 
6. For detailed O-ring assembly sequence , refer to clause 2, step i. to step viii. of Section 5.7.2 
Chassis Reassembly  on page 5-14.
7. Reassemble the chassis assembly followed by in stalling into Front Cover. (Refer to Section 
5.7 Radio Reassembly – Detailed  on page 5-12).
8. Inspect the main seal O-ring fo r proper seating. Observe carefully to ensure that the main 
seal O-ring is not pinched betwe en the housing and the chassis.
5.8.9.3  Battery Contact Seal
To replace the Battery Contact Seal:
1. Refer to Section 5.6 Radio Disassembly – Detailed  on page 5-5 to remove the Battery Con-
tact Seal.
2. Remove the Battery Contac t Seal from the Chassis.
3. Inspect the Battery Contact Seal, Chassis and  surrounding areas for foreign material that 
might prevent the Battery Contact Seal from sealing properly. 
4. Install a new Battery Contact Seal; discard the old Seal. 
5. Replace a new main seal O-ring; discard the old O-ring. 
6. Reassemble the chassis assembly followed by in stalling into Front Cover. (Refer to Section 
5.7 Radio Reassembly – Detailed  on page 5-12).
7. Inspect the main seal O-ring fo r proper seating. Observe carefully to ensure that the main 
seal O-ring is not pinched betwe en the housing and the chassis.
IMPORTANT: Both Breathing Vent Label (3371478L01) and Breathing Vent Membrane 
(3271570L01) need to be replaced after vacuum test, pressure test or 
water leakage troubleshooting.
NOTEWhen installing the assembled cha ssis to the Front Cover, ensure the O-ring at the top two
corners are not dislodged from the chassis groove. 
						

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-23
5.8.9.4  Breathing Vent Membrane and Breathing Vent Label
To replace the Breathing Vent Membrane and Breathing Vent Label:
1. Remove the Breathing Vent Label that covers  the Breathing Vent Membrane from the chas-
sis.
2. Remove the Breathing Vent Membrane.
3. Ensure that the chassis’s surface (at the Br eathing Vent Label & Breathing Vent Membrane 
recessed) is clean, no/minimum scratches and free from any adhesive or other foreign mate-
rials.
4. Install a new Breathing Vent Membrane, covering the vent port hole, in the small recessed 
area in the chassis. Ensure that no oily substance come in contact with the seal.
5. Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed 
area in the chassis. Press down evenly over  the label’s surface to ensure good adhesion. 
						

							5-24Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
5.8.10 Troubleshooting Charts
Troubleshooting Flow Chart for Va cuum Test (Sheet 1 of 2)
Start
1 . Remove  Battery
2 . Remove  Universal 
Connector  Dustcover
3 . Remove  breathing  vent label 
and  membrane
1 . Attach  antenna  firmly to  the  radio.
2 .  Attach  vacuum  hose to vacuum 
pump
3 .  Ensure  fitting seal is attached  to  
hose-to-chassis pump  connector
4 .  Screw  pump  connector  into  chas-
sis’ s tapped  hol e
5 .  Attach  vacuum  hose to  pu mp
 
con

nector
6 .  P lace  radio on  flat  surface
7 .  Operate  pump  (gauge  = 6 in.  Hg)
Gauge
does  not fall 
bel ow 
0 .5  in. Hg NO
Y ES
Run  Pressure  Te s t
1 .Repl ace Breath-
ing  Ve n t  labe l and 
Breathing  Ve n t 
Membrane
2 . Radio  approved  
for immersibil ity
Full 
e quipment  for
pressure  test
procedure avail able Y
ES
NO
B 
End
A 
						

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-25
Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)
StartB
1 Remove  pump and
connectors from radio
2. Remove antenna
3. Separate front housing kit 
Examine  and
reassembl e
main O-ring Repl ace front
housing  kit with
new  unitReplace main
O-ring with new unit Repl ace new
chassis  kit
without  PCBs 
Y
ES
NO NONONO
Changed
front  housing
kitY ESChanged
back  chassis
kitY ESChanged
main  O-ringExamined
main O-ring fitting 

YES
Send  radio to
Motorola Depot or
Motorola Service  Center
End
A 
						

							5-26Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
Troubleshooting Flow Chart for Pressure Test & Leakage Areas
Start
1 . Remove  vacuum  hose from 
pump  connector
2 . Attach  pressure  hose to 
pump  connector
1 . Operate  pressure  pump 
(pressure  = 1 psig)
2 . I mmerse  radio  into a  water-
fill ed  container
Continuous  
Series  of  
bubbl es Y
ES
NO
Bubbl es from 
Front  
Housing Y
ES
NO
Bubbl es from  
Chassis Y
ES
NO
Bubbl es from  
Battery  Con-
tact  Sea l Y
ES
NO
Bubbl es from  
Lens* /U niver-
sal  Connector/  
chassis/ 
Housing  Inter-
face/  PTT   1
.  Dry  the  radio
2 .  Rep lace  Housing , Main  
Sea l O-Ring,  and repeat 
steps  in Troubl eshooting  
F low  Chart  for Va c u u m  Te s t .YES
1.  Remove  Knobs
NO
1. Dry  the radio
2 . Repl ace Battery  Contact  Seal, 
Main  Seal  O-Ring, and  repeat 
steps  in Troub leshooting  F low 
Chart  for  Vacuum  Te s t.
1
. Dry  the radio
2 . Repl ace Main  Seal O-ring,
and  repeat  steps in 
Troub leshooting  F low  Chart 
for  Vacuum  Te s t.
1
.  Dry  the radio
2 .Re p
lace  Bre
 athing
Vent  labe l and 
Breathing  Vent  
Membrane
3 . Radio  approved 
for  immersibil ity * 
Onl y for  Disp lay  Mode l
EndEndEndEndEnd 
						

							Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-27
5.9 Radio Exploded Mechanical Views and Parts Lists
5.9.1 Display Model Exploded View and Parts List
Figure 5-21.  Display Model Exploded View
1
2
3
4
5
6
7
8910
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
15 
						

							5-28Disassembly/Reassembly Procedures : Radio Exploded Mechanical Views and Parts Lists
Table 5-3.  Display Model Exploded View Parts List
Item Description Part Number
1Screw with Washer0371981L01
2 Screw, Speaker Retainer 0386434Z02
3Retainer, Speaker4271352L02
4 Speaker 5085798F09
5Assembly, Front HousingPMLN4646_
6 Nameplate for DP 3601 Nameplate for DP 3600 3371390L03
3371390L04
7Cover, Dust1571477L01
8 Antenna Refer to separate  Accessory List Leaf-
let 6866574D04
9Knob, Frequency3615204H01
10 Knob, Volume 3615205H01
11Module, Display7215182H01
12 Screw 0386104Z04
13Board, Interface0104022J35
14 Retainer, Display 4215189H01
15Clip, Shield4271320L01
16 Shield, Can 2615156H01
17Back Cover KitSee Section 1.4: 
Model Charts
18 Pad, Thermal 7515526H01
19O-ring, Chassis3215181H01
20 Retainer, O-ring 4216293H01
21Retainer, O-ring4216292H01
22 Assembly, Chassis Molded w/ MIP Shield 0104023J31
23Seal, Battery Contact3215177H02
24 Screw 0316281H01
25Seal, Pot3271570L01